US10934225B2 - Compaction of polyhalite and potash mixture - Google Patents

Compaction of polyhalite and potash mixture Download PDF

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US10934225B2
US10934225B2 US16/623,074 US201816623074A US10934225B2 US 10934225 B2 US10934225 B2 US 10934225B2 US 201816623074 A US201816623074 A US 201816623074A US 10934225 B2 US10934225 B2 US 10934225B2
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particles
polyhalite
screener
mixture
potassium
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US20200157014A1 (en
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Ruben SOCOLOVSKY
Khalil Abu-Rabeah
Ayoub ALHOWASHLA
Yacov LEVY
Natalia GEINIK
Nizbert MAVHUNGA
Ofir COHEN
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ICL Europe Cooperatief UA
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Assigned to ICL EUROPE COOPERATIEF U.A. reassignment ICL EUROPE COOPERATIEF U.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALHOWASHLA, Ayoub, COHEN, Ofir, ABU-RABEAH, KHALIL, GEINIK, Natalia, LEVY, Yacov, MAVHUNGA, Nizbert, SOCOLOVSKY, Ruben
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    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05D—INORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C; FERTILISERS PRODUCING CARBON DIOXIDE
    • C05D1/00—Fertilisers containing potassium
    • C05D1/005—Fertilisers containing potassium post-treatment
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05D—INORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C; FERTILISERS PRODUCING CARBON DIOXIDE
    • C05D1/00—Fertilisers containing potassium
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05D—INORGANIC FERTILISERS NOT COVERED BY SUBCLASSES C05B, C05C; FERTILISERS PRODUCING CARBON DIOXIDE
    • C05D9/00—Other inorganic fertilisers
    • C05D9/02—Other inorganic fertilisers containing trace elements
    • C—CHEMISTRY; METALLURGY
    • C05—FERTILISERS; MANUFACTURE THEREOF
    • C05G—MIXTURES OF FERTILISERS COVERED INDIVIDUALLY BY DIFFERENT SUBCLASSES OF CLASS C05; MIXTURES OF ONE OR MORE FERTILISERS WITH MATERIALS NOT HAVING A SPECIFIC FERTILISING ACTIVITY, e.g. PESTICIDES, SOIL-CONDITIONERS, WETTING AGENTS; FERTILISERS CHARACTERISED BY THEIR FORM
    • C05G5/00—Fertilisers characterised by their form
    • C05G5/10—Solid or semi-solid fertilisers, e.g. powders
    • C05G5/12—Granules or flakes

Definitions

  • the present invention relates to the field of fertilizers, specifically to production of compacted polyhalite and potash mixture to act as a fertilizer.
  • plants need nutrients (nitrogen, potassium, calcium, zinc, magnesium, iron, manganese, etc.) which normally can be found in the soil.
  • nutrients nitrogen, potassium, calcium, zinc, magnesium, iron, manganese, etc.
  • fertilizers are needed to achieve a desired plant growth as these can enhance the growth of plants.
  • Fertilizers typically provide, in varying proportions, three main macronutrients:
  • Potassium (K) Strong stem growth, movement of water in plants, promotion of flowering and fruiting
  • micronutrients copper (Cu), iron (Fe), manganese (Mn), molybdenum (Mo), zinc (Zn), boron (B), and of occasional significance there are silicon (Si), cobalt (Co), and vanadium (V) plus rare mineral catalysts.
  • slow release fertilizers SRF
  • controlled release fertilizers CRF
  • slow release fertilizers and controlled release fertilizers differ in many ways: The technology they use, the release mechanism, longevity, release controlling factors and more.
  • Solid fertilizers include granules, prills, crystals and powders.
  • a prilled fertilizer is a type of granular fertilizer that is nearly spherical made by solidifying free-falling droplets in air or a fluid medium.
  • Most controlled-release fertilizers (CRFs) used in commercial nurseries are prilled fertilizers that have been coated with sulfur or a polymer. These products have been developed to allow a slow release of nutrients into the root zone throughout crop development.
  • Polyhalite is an evaporite mineral, a hydrated sulfate of potassium, calcium and magnesium with formula: K 2 Ca 2 Mg(SO 4 ) 4 .2H 2 O. Polyhalite is used as a fertilizer since it contains four important nutrients and is low in chloride:
  • Potash refers to potassium compounds and potassium-bearing materials, the most common being potassium chloride (KCl). Potassium is the third major plant and crop nutrient after nitrogen and phosphorus. It has been used since antiquity as a soil fertilizer (about 90% of current use). Elemental potassium does not occur in nature because it reacts violently with water. As part of various compounds, potassium makes up about 2.6% of the weight of the Earth's crust and is the seventh most abundant element, similar in abundance to sodium at approximately 1.8% of the crust. Potash is important for agriculture because it improves water retention, yield, nutrient value, taste, color, texture and disease resistance of food crops. It has wide application to fruit and vegetables, rice, wheat and other grains, sugar, corn, soybeans, palm oil and cotton, all of which benefit from the nutrient's quality enhancing properties.
  • KCl potassium chloride
  • a process for the compaction of Polyhalite with a Potassium salt comprising: mixing a feed of polyhalite with a feed of said Potassium salt in a mixer to yield a mixture; compacting said mixture in a compactor to yield masses; crushing said masses in a crusher to yield particles; and screening said particles in a screener to yield different particles in three different sizes: oversized particles which undergo a second crushing process and are retuned to said screener for screening, undersized particles which are transferred to said mixer for further mixing, and desired size granular particles which are transferred to a polish screener.
  • the Potassium salt may include at least one of Potash, Potassium Nitrate and Potassium Sulphate, or any other form of Potash.
  • the process may be a wet process including the addition of a binder.
  • the binder may be added to the mixer with said feed of polyhalite and said feed of Potassium salt.
  • the binder may be selected from the group including starch, bentonite, sodium silicate, lignosulfonates, molasses, hydrated lime, bitumen, Portland cement, clay, acids (nitric, hydrochloric, phosphoric, sulphuric), cellulose gum, sucrose, water, water glass, cements, Fly Ash, Potassium and Sodium Silicate, MgO, CaO, Alganite, Geo-polymers, oils and waxes and the like, or a combination thereof.
  • the process is a dry process wherein said mixture is heated in a heater after being mixed in said mixer.
  • FIG. 1 is a schematic illustration of a wet process for the compaction of Polyhalite and a potassium salt in accordance with some demonstrative embodiments.
  • FIG. 2 is a schematic illustration of a dry process for the compaction of Polyhalite and potassium salt in accordance with some demonstrative embodiments.
  • a process for the compaction of a polyhalite and potash mixture (the mixture may also be referred to as “PotahPlus®”).
  • a compacted polyhalite and potash mixture there is provided a compacted polyhalite and potash mixture.
  • a process for mixing Potash with Polyhalite wherein the concentration of Potash in the mixture may be in the range between 0%-95% w/w Potash.
  • the process may preferably include compacting of 50% w standard Potash and 50% w Polyhalite.
  • the compaction may a dry compaction and according to other embodiments, the compaction may be a wet compaction.
  • the compaction process may include the addition of a binder.
  • the binder may include but not limited to any suitable material or compound that may mechanically and/or chemically hold or draw other materials together to form a cohesive whole, including, for example, organic or inorganic binders, such as, starch, bentonite, sodium silicate, lignosulfonates, molasses, hydrated lime, bitumen, Portland cement, clay, acids (nitric, hydrochloric, phosphoric, sulphuric), cellulose gum, sucrose, water, water glass, cements, Fly Ash, Potassium and Sodium Silicate, MgO, CaO, Alganite, Geo-polymers, oils and waxes and the like, or a combination thereof.
  • organic or inorganic binders such as, starch, bentonite, sodium silicate, lignosulfonates, molasses, hydrated lime, bitumen, Portland cement, clay, acids (nitric, hydrochloric, phosphoric, sulphuric), cellulose gum, sucrose, water, water
  • the binder may be added in a concentration ranging between 0.5-20% w/w, preferably between 3-7% w/w.
  • the addition of a binder to the process improves the compaction process, enhances the strength of the resulting granules (also referred to herein as flakes) and diminishes the abrasion of the final product, e.g., when the final resulting product is transported).
  • the resulting product may have a low abrasion level.
  • the compaction when the compaction is a wet compaction, in addition to the binder, water may be added as well.
  • the compaction may be conducted at high feeding temperatures.
  • the quality of the compacted product may be higher as the Potash level increases.
  • the dry compaction process may include the following steps:
  • the mixture may be heated to a temperature between 80-180° C., preferably 160° C.
  • a binder in the dry process, optionally a binder may be added in a concentration of between 0.01-7% w/w, preferably between 1-5% w/w, most preferably between 2-4% w/w.
  • oil may be added to the resulting granules, e.g., to improve the rheology of the product and diminish dust formation. For example in an amount between 3000-5000 ppm, preferably 3000 ppm.
  • any suitable oil may be used, including for example, mineral oil or similar, slack wax or similar, paraffin wax or similar or mixture of them
  • the process may include unique conditions to enable to effective compaction of Potash and Polyhalite, including high temperatures ranging from 80 to 190° C. preferably 160° C. and high force conditions ranging from 45 to 100 kN/cm, preferably 55 kN/cm and Flack thickness between 1.4 mm to 33 mm.
  • the desired size of the flakes is between 1-6 mm, most preferably between 2-4 mm.
  • the present invention allows for the effective compaction of polyhalite which is difficult to compact under regular conditions due to the difficulty in achieving deformation of polyhalite particles.
  • the addition of Potash, Phosphate compounds or Potassium Nitrate to Polyhalite and the unique conditions described herein enable to overcome the difficulties of compacting Polyhalite and to effectively provide compacted granules of with addition of phosphate compounds, Potassium Nitrate or Potassium Sulfate
  • the process of the present invention may also be effective when Potash is replaced with Potassium Nitrate and/or Potassium Sulphate.
  • the Phosphates compounds or Potassium Nitrate will be added to Polyhalite and the unique conditions described herein enable to overcome the difficulties of compacting Polyhalite and to effectively provide compacted granules of polyhalite with potash, phosphate compounds or potassium Nitrate or Potassium Sulfate optionally with addition of a binder.
  • the process may include wet compaction, wherein the process is carried out in a temperature ranging from room temperature ( ⁇ 25° C.) to 100° C.
  • the process includes the following steps:
  • the wet compaction process includes heating the desired size granules in order to evaporate any water residues from the granules, resulting in dry granules.
  • the granules are heated to a temperature of between 100-160° C., preferably 140° C.
  • the wet compaction process allows for the compaction of polyhalite at high concentrations from 10% to 100%, preferably 59% of polyhalite.
  • the binder suspension may include a binder which is immersed in water, wherein the binder in the wet process is preferably fly ash, calcium oxide and/or calcium hydroxide.
  • additives may be added, including for examples, nutrients, minerals, coating materials, sustained release compounds and the like.
  • the nutrients may include:
  • Potassium (K) Strong stem growth, movement of water in plants, promotion of flowering and fruiting
  • micronutrients copper (Cu), iron (Fe), manganese (Mn), molybdenum (Mo), zinc (Zn), boron (B), and of occasional significance there are silicon (Si), cobalt (Co), and vanadium (V) plus rare mineral catalysts.
  • the mixture of the present invention may also include additional fertilizer besides Potash and Polyhalite.
  • the term “fertilizer” may include any material of natural or synthetic origin that is applied to soils or to plant tissues to supply one or more plant nutrients essential to the growth of plants, including, for example, Single nutrient (“straight”) fertilizers such as Ammonium nitrate, Urea, calcium ammonium nitrate, superphosphate, e.g., “Single superphosphate” (SSP), phosphogypsum, Triple superphosphate (TSP) or a mixture thereof; Multinutrient fertilizers such as Binary (NP, NK, PK) fertilizers, e.g., monoammonium phosphate (MAP) and/or diammonium phosphate (DAP), NPK fertilizers which are three-component fertilizers providing nitrogen, phosphorus, and potassium; fertilizers which include one or more of the main micronutrients sources of iron, manganese, boron, molybdenum, zinc, and copper and the like; Compound fertilizers, e.g., which contain N
  • the fertilizer preferably includes one or more of nitrogen fertilizers such as ammonia, anhydrous ammonium nitrate, urea and sodium nitrate; Phosphate fertilizers; Potassium fertilizers, such as Potash, potassium chloride, potassium sulfate, potassium carbonate, or potassium nitrate
  • nitrogen fertilizers such as ammonia, anhydrous ammonium nitrate, urea and sodium nitrate
  • Phosphate fertilizers such as Potash, potassium chloride, potassium sulfate, potassium carbonate, or potassium nitrate
  • the fertilizer is preferably Ammonium Sulphate.
  • the sieving is done using a siever having opening with a diameter of between 1.4-4.5 mm preferably between 2-4 mm, most preferably 3.4 mm.
  • the mixing is performed in a blade blender and/or any other suitable devise capable of having a rotation speed that creates a swirling motion for a perfect homogenization and a high blending precision, e.g., a Ploughshare® Mixer.
  • the resulting flakes/granules may be glazed and further coated with a suitable coating.
  • the coatings may include biodegradable coatings, sustained release coatings, controlled release coatings, oily coatings, wax coatings.
  • the resulting Polyhalite and potash mixture may include the following properties as detailed in table 1
  • the resulting Polyhalite and potash compacted product mixture may include the following particle size distribution as detailed in table 2
  • the resulting Polyhalite and potash mixture may include the following properties as detailed in table 3
  • FIG. 1 depicts a wet process 100 for the compaction of Polyhalite and Potash in accordance with some demonstrative embodiments described herein.
  • wet process 100 may include a binder preparation step 108 .
  • preparation step 108 can include the following steps: binder heating, mixing, grinding, activation, dissolution and curing, Step 106 depicts the addition of the binder to a pre-mixer 110 , in which the pre-mixer 110 saves the homogenous composition of the binder mixture.
  • the binder is then added to a mixer 112 to which a feed of Polyhalite 102 is added together with a feed of Potash 104 .
  • the Polyhalite, Potash and binder are homogenously mixed together to create a Polyhalite/Potash wet mixture (“the mixture”).
  • the mixture may then be transferred to a compactor 114 to undergo compaction.
  • the compactor may work in the follow conditions: high or low temperatures ranging from 80 to 190° C. preferable 150° C. and high force conditions ranging from 45 to 100 kN/cm, preferable 55 kN/cm and Flack thickness between 4 mm to 40 mm.
  • the mixture leaves compactor 114 as compacted masses which are then transferred to a crusher 116 , and the masses are then crushed to finer particles in a size ranging from 0.1 mm to 20 mm
  • the particles may undergo primary screening in a screener 118 with multiple decks between 1 mm to 6 mm, preferably 1, 2 and 5 mm.
  • undersized particles 134 and/or any dust that may be formed while passing through screener 118 can be separately granulated and/or introduced back to the process, e.g., to mixer 112 to be mixed again with the mixture.
  • the range of the undersized particles 134 and/or any dust that may be formed while passing through screener 118 can be between 0.1 to 1 mm.
  • Oversized particles 138 may go at least one crushing procedure to be crushed to a desired size.
  • OS 138 may be transferred to crusher 120 and undergo a secondary screening in screener 122 . Any particles having a desired size ranging between 0.1 mm to 20 mm that may result from screener 122 may be added back to screener 118 .
  • Oversized particles 142 that result from screener 122 may undergo additional crushing in crusher 124 , wherein particles yielded from crusher 124 are added back to screener 118 for further processing.
  • the differences between crusher 120 and 124 may be hammer mill or other kind of crushers.
  • the desired sized particles leaving screener 118 may go through a process of drying to drying any residual moisture from the particles and to yield dry particles.
  • the dry particles are then transferred to a polishing screener 128 to undergo an additional, finer, screening process 1 mm to 6 mm preferably 2 mm to 4 mm.
  • a polishing screener 128 to undergo an additional, finer, screening process 1 mm to 6 mm preferably 2 mm to 4 mm.
  • the undersized particles 136 may be transferred back to mixer 112 to be mixed again with the mixture.
  • Oversized particles 140 may go through a crushing procedure to be crushed to a desired size.
  • OS 140 may undergo crushing in crusher 124 , wherein particles yielded from crusher 124 are added back to screener 118 for further processing.
  • the final particles yielded from polishing screener 128 may go through a process of glazing in glazer 130 .
  • the grazing system may prevent the abrasion and dust pollution during the transport.
  • Glazer 130 may include a rotary drum, a drying can, various types of dryers, e.g., fluid bed dryer, or others
  • FIG. 2 depicts a dry process 200 for the compaction of Polyhalite and Potash in accordance with some demonstrative embodiments described herein.
  • dry process 200 may include a feed of Polyhalite 202 which is added together with a feed of Potash 204 to a mixer 206 .
  • the Polyhalite and Potash are homogenously mixed together to create a Polyhalite/Potash dry mixture (“the dry mixture”).
  • the dry mixture may then be transferred to a Heater 208 to heat the material to compacting process between 80 to 190 degrees, preferably 170 degrees.
  • the heated dry mixture may then be transferred to a compactor 210 to undergo compaction and yield compacted masses.
  • the compaction parameters may include high temperatures ranging from 80 to 190° C. preferably 150° C. and high force conditions ranging from 45 to 100 kN/cm, preferable 55 kN/cm and Flack thickness between 14 mm to 37 mm.
  • the compacted masses are then transferred to a crusher 212 , and the masses are then crushed to finer particles
  • the particles may undergo primary screening in a screener 214 with multiple decks between 1 mm to 6 mm, preferable 1, 2 and 5 mm.
  • undersized particles 228 and/or any dust that may be formed while passing through screener 214 can be separately granulated and/or introduced back to the process, e.g., to mixer 206 or heater 208 .
  • the range of the undersized particles 228 and/or any dust that may be formed while passing through screener 214 can be between 0.1 to 1 mm.
  • the undersized particles 228 may be transferred back to heater 208 .
  • Oversized particles 232 may go at least one crushing procedure to be crushed to a desired size.
  • OS 232 may be transferred to crusher 222 and undergo a secondary screening in screener 224 .
  • Any particles having a desired size ranging between 1 to 6 mm preferable 2 mm to 4 mm that may result from screener 224 may be added back to screener 214 .
  • Oversized particles 236 that result from screener 224 may undergo additional crushing in crusher 226 , wherein particles yielded from crusher 226 are added back to screener 214 for further processing.
  • the differences between crusher 222 and 226 may be the kind of crusher and operational parameters.
  • the desired sized particles leaving screener 214 may go through a polishing screener 216 to undergo an additional, finer, screening process. 1 to 6 mm preferable 2 mm to 4 mm According to some demonstrative embodiments, from polishing screener 216 there may be yielded particles in 3 different size ranges:

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Pest Control & Pesticides (AREA)
  • Processing Of Solid Wastes (AREA)
  • Fertilizers (AREA)
  • Cultivation Of Plants (AREA)
  • Crushing And Grinding (AREA)
  • Disintegrating Or Milling (AREA)
US16/623,074 2017-06-15 2018-06-12 Compaction of polyhalite and potash mixture Active US10934225B2 (en)

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US201762519903P 2017-06-15 2017-06-15
PCT/IL2018/050639 WO2018229757A1 (fr) 2017-06-15 2018-06-12 Mélange compacté de polyhalite et de potasse et son procédé de production
US16/623,074 US10934225B2 (en) 2017-06-15 2018-06-12 Compaction of polyhalite and potash mixture

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US20210395158A1 (en) * 2018-11-23 2021-12-23 Icl Europe Cooperatief U.A. Compacted polyhalite and a process for the production thereof

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RU2020124416A (ru) 2018-02-27 2022-03-29 Дед Си Воркс Лтд. Способ гранулирования пылеобразного поташа
US20220298084A1 (en) * 2019-08-22 2022-09-22 Icl Europe Cooperatief U.A. Granules of polyhalite, potash and ammonium sulphate and a compaction process for the production thereof
CN113518769A (zh) * 2019-09-24 2021-10-19 艾斯尔欧洲合作社公司 杂卤石和尿素的颗粒物
GB2616186B (en) * 2019-10-25 2024-05-29 Anglo American Woodsmith Ltd Composite Fertiliser Systems
EP4085038A4 (fr) * 2020-01-03 2024-01-24 ICL Europe Cooperatief U.A. Granulé de polyhalite et de sop et son procédé de production
EP4097068A4 (fr) * 2020-01-27 2024-02-14 ICL Europe Cooperatief U.A. Granulé de polyhalite et de sulfate d'ammonium et son procédé de compactage pour leur production
EP4097069A4 (fr) * 2020-01-27 2024-02-21 ICL Europe Cooperatief U.A. Granulé d'engrais comprenant du polyhalite et de sulfate de potassium et procédé de compactage pour la production de celui-ci
US20230250037A1 (en) * 2020-01-27 2023-08-10 Icl Europe Cooperatief U.A. Granules of polyhalite and urea and a compaction process for the production thereof
CN115038679A (zh) * 2020-02-21 2022-09-09 奥斯特拉营养康复技术有限公司 缓慢释放的钾和硫肥料及其制造方法
IL297989A (en) * 2020-05-24 2023-01-01 ICL Europe Cooperatief UA Fertilizer granule of polyhalite and molten urea and a process to create it
CA3185508A1 (fr) 2020-06-10 2021-12-16 Tessenderlo Group Nv Granules d'engrais mixtes
US20230312429A1 (en) * 2020-08-13 2023-10-05 Icl Europe Cooperatief U.A. Granules of polyhalite and phosphogypsum and a process for the production thereof
EP4008705A1 (fr) 2020-12-04 2022-06-08 K+S Aktiengesellschaft Procédé de fabrication de granulés contenant du potassium, du magnésium et du sulfate
WO2022144868A1 (fr) * 2020-12-28 2022-07-07 Icl Europe Cooperatief U.A. Granulés de polyhalite et de dolomite
US20240308928A1 (en) * 2021-02-16 2024-09-19 Icl Europe Cooperatief U.A. Kaoline binders for fertilizers

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CA3066985A1 (fr) 2018-12-20
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ES2964035T3 (es) 2024-04-03
EP3638641A1 (fr) 2020-04-22
US20200157014A1 (en) 2020-05-21
CL2019003604A1 (es) 2020-11-06
EP3638641B9 (fr) 2023-12-06
IL271481A (en) 2020-01-30
CO2019015080A2 (es) 2020-01-17
BR112019026669A2 (pt) 2020-06-30
IL271481B2 (en) 2024-01-01
IL271481B1 (en) 2023-09-01
WO2018229757A1 (fr) 2018-12-20
PL3638641T3 (pl) 2024-03-04

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